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United States Patent (19) 11 Patent Number: 5,034,441 Nakano Et Al

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United States Patent (19) 11 Patent Number: 5,034,441 Nakano Et Al United States Patent (19) 11 Patent Number: 5,034,441 Nakano et al. 45 Date of Patent: Jul. 23, 1991 54 STYRENE-BASED RESIN COMPOSITION (56. References Cited AND PROCESS FOR PRODUCING U.S. PATENT DOCUMENTS MOLDING PRODUCTS THEREOF 4,463,113 7/1984 Nakahara et al. ................... 524/117 4,619,959 10/1986 Matsubara et al. .. ... 524/228 75) Inventors: Akikazu Nakano; Takashi Sumitomo, 4,680,353 7/1987 Ishihara et al. .. ... 526/59 both of Ichihara, Japan 4,820,772 4/1989 Goto et al. .......................... 524/117 73 Assignee: Idemitsu Kosan Co., Ltd., Tokyo, Primary Examiner-Joseph L. Schofer Japan Assistant Examiner-Mark D. Sweet Attorney, Agent, or Firm-Frishauf, Holtz, Goodman & (21) Appl. No.: 559,971 Woodward 57 ABSTRACT (22 Filed: Jul. 27, 1990 Disclosed is a styrene-based resin composition which comprises (a) 100 parts by weight of styrene-based poly Related U.S. Application Data mer having a high degree of syndiotactic configuration, 63 Continuation-in-part of Ser. No. 470,975, Jan. 26, 1990, (b) 0.01 to 15 parts by weight of at least one nucleating abandoned. agent selected from an organophosphorus compound and a metal salt of an organic acid, and (c) 0.01 to 15 (30) Foreign Application Priority Data parts by weight of at least one component selected from a polyoxyalkylene compound, a fatty acid and a deriva Feb. 2, 1989 (JP) Japan .................................... 1-22587 tive thereof. 51 Int. Cli................................................ C08K 5/15 The composition can produce various molding prod 52 U.S. C. .................................... 524/117; 524/127; ucts with excellent mold-releasing property, surface 524/377; 524/385; 524/388; 524/307; 524/228; gloss, bending strength, bending modulus and heat resis 524/577; 524/394 tance. 58) Field of Search ............... 524/117, 127, 228,377, 524/385, 388 6 Claims, No Drawings 5,034,441 1. 2 Another object of the present invention is to provide STYRENE-BASED RESIN COMPOSITION AND a process for efficiently producing the molding product PROCESS FOR PRODUCING MOLDING with excellent properties described above. PRODUCTS THEREOF The present invention provides a styrene-based resin 5 composition which comprises (a) 100 parts by weight of This application is a continuation-in-part of U.S. ap styrene based polymer having a high degree of syndi plication Ser. No. 07/470,975, filed Jan. 26, 1990, now otactic configuration, (b) 0.01-15 parts by weight of a abandoned. nucleating agent consisting of at least one component selected from an organophosphorus compound and a BACKGROUND OF THE INVENTION 10 metal salt of an organic acid, and (c) 0.01-15 parts by 1. Field of the Invention weight of at least one component selected from a poly The present invention relates to a styrene-based resin oxyalkylene compound, a fatty acid and a derivative composition and process for producing molding prod thereof. The present invention also provides a process ucts thereof, more specifically it relates to a styrene for producing molded products (molding products) based resin composition which comprises a styrene 15 which process comprises molding said styrene-based based polymer having a high degree of syndiotactic resin composition with a die at a low temperature. configuration and specific components mixed there The styrene-based resin composition in the present with, and a process for producing molding products invention is composed essentially of (a), (b) and (c). prepared from the composition, which has a high crys Here, the syndiotactic configuration in styrene-based tallinity, an excellent surface gloss property and an 20 polymer of the (a) component means that its stereo excellent mold-releasing property. chemical structure is a syndiotactic configuration, i.e., 2. Description of the Related Arts having a stereo structure in which phenyl groups or A styrene based polymer produced by the radical substituted phenyl groups are located as side chains polymerization method, etc. has an atactic configura alternatively in opposite directions relative to the main tion in stereostructure. It is molded into various shapes 25 by various molding methods such as injection molding, chain consisting of carbon-carbon bonds. Tacticity is extrusion molding, blow molding, vacuum forming and quantitatively determined by the nuclear magnetic reso flow-in molding, for example, and is widely used for nance method using a carbon isotope (13C-NMR electric domestic appliances, office equipments, domes method). tic appliances, packaging, toys, furnitures, synthetic 30 The tacticity, as determined by the 13C-NMR papers and other industrial materials. However, the method, can be indicated in terms of the proportions of styrene-based polymer having an atactic configuration structural units connected continuously to each other, has drawbacks of insufficient mechanical strength, heat i.e., a diad in which two structural units are connected resistance and chemical resistance since it is not crystal to each other, a triad in which three structural units are lized. 35 connected to each other, or a pentad in which five The group of the present inventors have succeeded to structural units are connected to each other. The sty develop a styrene-based polymer having a high degree rene-based polymers having a high degree of syndiotac of syndiotacticity, and also developed a composition in tic configuration have such a syndiotactic configuration which other components are blended with the styrene that the proportion of racemic diad is at least 75% and based polymer (Japanese Patent Application Laid-Open preferably at least 85%, or the proportion of racemic Nos. 1048.18/1987,257948/1987 and 257950/1987). This pentad is at least 30% and preferably at least 50% in styrene-based polymer having a high degree of syndi syndiotacticity. The styrene-based polymers having a otactic configuration or a composition thereof has ex high degree of syndiotactic configuration in the present cellent mechanical strength, heat resistance, solvent invention include polystyrene, poly(alkylstyrene), resistance and electric characteristic as compared with 45 poly(halogenated styrene), poly(alkoxystyrene), poly(- a styrene-based polymer having an atactic configuration vinyl benzoate ester) and mixtures thereof, and copoly and its composition. However, the molding product mers containing them as main components. The above obtained by using the styrene-based polymer having a poly(alkyl styrene) includes poly(methylstyrene), poly high degree of syndiotacticity as a raw material requires (ethylstyrene), poly(isopropylstyrene), poly(tert-butyls high molding temperature to crystallize. 50 tyrene), poly(vinyl benzene), etc, and the poly(- In Japanese Patent Application Laid-Open No. halogenated styrene) includes poly(chlorostyrene), 201350/1989, there is proposed to accelerate the crys poly(bromostyrene), poly(fluorostyrene), etc. The tallization of a styrene-based polymer having a syndi poly(alkoxystyrene) also includes poly(methoxysty otactic configuration by blending a specific nucleating rene), poly(ethoxystyrene), etc. The most preferred agent, and the mold-releasing property and appearance 55 styrene-based polymers are polystyrene, poly(p-meth of the molding products therefrom have been im ylstyrene), poly(m-methylstyrene), poly(tert-butyl sty proved. rene), poly(p-chlorostyrene), poly(m-chlorostyrene), According to this technique, while physical proper poly(p-fluorostyrene), and a copolymer of styrene and ties or appearance of the composition or the molding p-methylstyrene. products obtained can be improved, there remains some 60 The molecular weight of the styrene-based polymer problems that crystallization rate is insufficiently high used in the present invention is not critical, but the and surface gloss of the molding products is poor. weight average molecular weight is preferably at least 10,000, and most preferably at least 50,000. The molecu SUMMARY OF THE INVENTION lar weight distribution is not critical, and the styrene An object of the present invention is to provide a 65 based polymers in various ranges of molecular weight styrene-based resin composition which can produce a can be applied. Styrene-based polymer with a weight molding product having a high crystallinity and a good average molecular weight of less than 10,000 is not appearance. suitable because the composition obtained and its 5,034,441 3 4. molded products have inferior thermal characteristics an alkyl group having 1 to 6 carbon atoms, and M and and mechanical strength. a are the same as defined above). The styrene-based polymers having a syndiotactic Specific examples of the organophosphorus com configuration can be produced by polymerizing sty pounds (b) represented by the general formula above rene-based monomers (corresponding to the above sty 5 (B-I) are shown below: rene-based polymers) using a catalyst comprising a tita nium compound and a condensate of water and trialkyl aluminium in, for example, an inert hydrocarbon sol O vent or in the absence of a solvent (Japanese Patent O- P-O-Na. Application Laid Open No. 187708/1987). 10 The component (b) of the resin composition in the 2 present invention consists of any one or both of a metal salt of an organic acid and an organophosphorus com O pound. The metal salt of an organic acid includes so I dium, calcium, aluminium or magnesium salt of benzoic 15 O- P-O-Ca/2 acid, p-(tert-butyl) benzoic acid, cyclohexane carbox 2 ylic acid (hexahydrobenzoic acid), amino benzoic acid, A-naphthoic acid, cyclopentane
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